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1971 CCW 340 Service Manual

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2. be adj ming usted e recheck plate cannot 50 1 cylinder Gap may be re adjusted to 0 014 desired timing sequence Break re within specitied tolerance 3ough to accurately breaker point gap 002 inch to obtain er point gap must zo QD into lig or and install 1 sconnect timi g Remove dial indica spar ig hole Di coupler h Adjust This 0 2 cylinde it from ignitior 06 014 inch neci one lead and the other 0 2 cylinder breaker point nt set has red ignition wiri af timing light to the red wire at cot lead to ground i Locate 2 pisto procedural step 9 Cor pl osition at true 0 Refer to D Contact Breaker retaining screws Plate retainings screws Fig 5 13 Adjusting Contact Breaker Points Rotate flywheel until pointer of dial indicator reaches 0 015 inch before true T D C At this instant the timing light should go out to indicate breaker points just starting to open If necessary point gap may be re adjusted to 0 014 002 inch to obtain the desired timing sequences Breaker point gap must remain within specified toler ance Recheck piston travel to verify timing accuracy k Replace window plate starter cup fan belt
3. mo Spark plug wires reversed Flywheel key missing sheared Faulty condenser Improper timing Faulty breaker points Unhooked spark retarding mechanism or spring broken Spark plugs improperly gapped or dirty Magneto breaker points improperly gapped or dirty Faulty coil or condenser Loose or broken magneto wires Blown head gasket Inlet lever adjustment too low Crankcase leaking Leaking cylinder head Magneto wires broken inside coil ground broken Cracked cylinder wali Defectivespark plug Breaker points improperly gapped Crankcase seal leaking C d CO b 6 Install new seal 1 Install wire correctly Replace key Replace condenser Re time engine Adjust or replace points Reconnect mechanism or replace spring Clean adjust or install new plugs Clean adjust or install new points Replace coil or condenser Repair or replace magneto wires Replace head gasket Refer to carburetor manufacturer Specifications Install new seal Check head for warps cracks Install new gasket and cylinder head Repair or replace wires Replace faulty cylinder Clean adjust or install new plug He adjust points to 7 gh speed needle set too lean Adjust carburetor Refer to Manufacturer sSpecifications well but dies down
4. udi Li ERE ub 10 x 10 THE 1 2 INCH CENTRE TAP LIGHTING COIL CCW 440 DENSO IGNITION 2 35 W SWITCH IS 70 SIMPLIFY CIRCUIT OMITTED dT 44414 70 60 40 100 INSERT PAGE MARCH 1971 5 3 0 R 6 65 41 Fig 2 9 70 Till RPM x 00 V N DHAN H ERED O H H E LIII epee pre HEUS Cue 9 n A AMPS CCW 440 CENTRE TAP LIGHTING COIL SWITCH 5 ONITTED TO SIMPLIFY CIRCUIT NOTE 5
5. 5 7 High Tension Ignition 5 7 Recoil Starter 5 7 Intake and Exhaust Manifolds 5 7 Covers 111 5 7 Engine Installation 5 7 TESTING AND OVERHAUL 5 7 ADJUSTMENTS 5 7 Carburetor 5 7 Spark Plugs 5 7 Contact Breaker 5 7 Engine Ignition Timing 5 7 Preferred Method 5 7 Alternate Method 5 8 Crankshaft Angle Versus Piston Travel 5 8 FIGURE NUMBER TITLE PAGE 1 1 MODEL KEC 340 400 LEFTSIDE 1 2 1 2 15 1 3 2 1 TWO STROKE ENGINE OPERATING PRINCIPLE 2 1 22 SAWAFUJI IGNITION SYSTEM 2 3 23 KOKUSAN IGNITION 5 5 2 3 2 4 LIGHTING SYSTEM MANUAL START Previous to Engine Serial Numbers 340 2903614 and 400 2809570 Light taken from lighting coil AC 12V 35W 2 5 2 5 LIGHTING SYSTEM ELECTRIC START Previous to Engine Serial Numbers 340 2903614 and 400 2809570 Lights powered from battery 2 5 2 6 LIGHTING SYSTEM MANUAL START 3408 only previous to serial number 340 2903614 Lights taken from lighting coil AC 12V 75W 2 6 2 7 LIGHTING SYSTEM MANUAL START Engine Serial Numbers 340 2903614 400 2809570 and subsequent One Headlamp 12 volt 3
6. 3 3 35 COVER REMOVED 3 3 36 REMOVING FLYWHEEL 3 4 3 7 FAN COVER CASE REMOVED 3 4 38 MAGNETO REMOVED 3 5 39 CYLINDER HEADS REMOVED 3 6 3 10 CYLINDERS REMOVED 3 6 3 311 REMOVING PISTONS 3 8 3 12 UPPER CRANKCASE HALF REMOVED 3 8 4 1 COVER ASSEMBLY 4 2 4 2 RECOILSTARTER ASSEMBLY 4 3 4 3 FLYWHEEL ASSEMBLY 3405 4 4 4 4 FLYWHEEL ASSEMBLY 340 340G 400 4 6 45 STATOR ASSEMBLY Sawafuji Ignition 4 7 4 6 STATOR ASSEMBLY Kokusan Ignition 4 8 4 7 PISTON AND CRANKSHAFT ASSEMBLY 4 9 48 OILSEALS IDENTIFICATION 4 9 49 COILPLATE ASSEMBLY Denso 440 4 11 4 10 FLYWHEEL ASSEMBLY 440 4 12 5 1 CRANKCASE LOWER HALF seal retaining circlips 5 1 5 2 CRANKCASE BOLT TORQUING SEQUENCE 5 2 5 3 INSTALLING PISTONS RINGS AND PINS 5 2 5 4 INSTALLING CYLINDERS 5 3 5 5 CYLINDER HOLD DOWN NUT TORQUING 5 3 5 6 INSTALLING CYLINDER HEADS 5 4 5 7 CYLINDER HEAD HOLD DOWN NUT TORQUING 5 4 58 STATOR ASSEMBLY INSTALLED 5 5 59 FAN COVER CA
7. Remove retaining nut 2 lockwasher 3 and flatwasher 4 from threaded shaft of reel hub 10 Manipulate friction plate 5 on reel hub until eye end of return spring 7 aligns with retaining slot 22 Remove friction plate Remove the three paw Remove return spring 7 spring Note position of plain end of ret retaining hole in reel hub f Remove reel 10 Unwind the rope lift and t knotted end from center hub of reel g Lift long rolled end of main spring 11 from t spring retaining pin in spring h Clean all parts except rope using a suitable cleaning solvent rope requires cleaning wash it in a solution of soap and water Thoroughly dry all parts after cleaning i Inspect all parts for obvious damage and wear c e s 6 D 8 and cup washer 9 irn spring in the spring ntie the fixed the case and carefully remove the 4 3 2 Assembly a Replace defective parts b Install main spring as follows 1 Secure main spring winding tool part number 43 0797 60 or equivalent tool circular end up in a suitable bench vise 2 Start with the long rolled end of main spring 11 and wind spring into circular end of tool in a clockwise direction 3 Remove tool from vise Grasp the tool by its handle and lower the tool with spring installed into case 12 4 Secure the long rolled end of spring over the fixed spring retaining pin Remove winding tool
8. 72 NOTE 11 main spring is to be installed without the use of a soring winding tool wind main spring into case in an anti clockwise direction Clockwise installation ihe winding too is necessary to ensure correct anti clockwise installation of the spring when tool is placed upside down in the case 44 FLYWHEEL ASSEMBLY SAWAFUJI MODEL 3405 See Fig 4 3 4 4 1 Disassembly NOTE Complete disassembly of flywheel assemblies should performed hy authorized dealers only The auto advance mechanism is pre set during manufacture and should require no further adjustment If inspec ion reveals governor parts or defective mag neis install a new flywheel assembly or return lywheel to overhaul facility Remove snap ring 2 securing breaker point cam 3 to flywheel collar using a suitable snap ring removal tool Lift cam off collar Check cam and collar for scoring and weer governor weight stop screw 10 for wear and security Replace defective parts 4 4 2 Assembly 4 Apply a light film of Lubriplate or equivalent to outer surface of flywheel collar b Reverse removal procedure Lubricate in accordance with Lubrication Chart Table 2 2 d Check mechanism operation 4 5 FLYWHEEL ASSEMBLY KOKUSAN MODELS 340E 3406 and all 400 MODELS See Figure 4 4 4 5 1 Disassembly NOTE Complete
9. 3 3 14 Fits Tolerances 3 9 REPAIR AND REPLACEMENT 4 1 4 1 GENERAL 4 1 4 2 FAN COVER 4 1 43 RECOIL STARTER 4 1 4 4 FLYWHEEL ASSEMBLY 3405 4 5 4 5 FLYWHEEL ASSEMBLY 340 3406 400 4 5 4 6 STATOR ASSEMBLY 3405 4 5 4 6 1 Contact Breaker Point 5 1 4 5 4 6 2 Condenser and Oil Felt 4 10 4 7 STATOR ASSEMBLY 340E 340G 400 1 10 4 7 1 Contact Breaker Point Set 4 10 4 7 2 Condenser Felt Pad 4 10 4 8 CRANKSHAFT 4 10 4 8 1 Oil Seal and Outer Bearing 4 10 4 9 STATOR ASSEMBLY 440 4 11 4 9 1 Contact Breaker Point Set 4 11 4 9 2 Condenser and Oil Felt 4 11 4 10 FLYWHEEL ASSEMBLY 440 4 12 REASSEMBL Y TESTING AND ADJUSTMENTS 5 1 5 1 5 2 5 2 1 5 2 2 5 2 3 5 2 4 5 2 5 5 2 6 5 2 7 GENERAL 5 1 REASSEMBLY 5 1 Crankcase Crankshaft 5 1 Pistons Pins Rings 5 1 Cylinders 5 2 Cylinder Heads 5 4 Stator Assembly 5 5 Fan Cover Case and Flywheel 5 5 Fan Cover Starter Cup and Fan Belt Pulley 5 6 Electric Starter
10. Models CCW 440 all models all versions are equipped with Denso ignitions comprised of two low voltage generating coils and two high voltage coils all of tho same polarity 1 8 TECHNICAL DATA Table 1 1 details specifications applicable to all models of the CCW 340 400 440 engines in service at the present time 1 9 TOOL REQUIREMENT The following is list of tools required for the overhaul and adjustment of models CCW 340 400 440 engines a Special Tools Tool Flywheel puller Part 43 0790 90 3 2 1 1 Tool Main Spring Starter Rewind 43 0797 60 Para 4 4 Tool Bearing puller crankshaft Part 43 079 1 70 Para 4 8 1 Tool Flywheel Locking Part 43 0798 40 Para 3 2 1 Tool Fan Pulley Locking 43 0792 50 Para 4 2 1 a Reference b Standard Tools 10 13 mm spanner 13 21 mm Box spanner and handle 22 mm spanner 22 mm socket wrench and ratchet Piston ring removal tool Piston ring compressor Piston ring groove cleaning tool Circlip removal tool Torque wrench pounds feet Dial indicator Degree wheel Feeler Gauge Spark plug tap Spark plug wire gauge Thread Cleaning tools Wire brush spark plugs Soft metal non ferrous Phillips screw driver set screw drivers Soft hammer Fig 1 1 Model 340 400 Engine Left Side View Flywheel end 1 2 CCWTOOL LIST 43 0797 60 REWIND SPRING TOOL 43 0791 70 BEARING PULLER 43 0790 90
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12. 1 Preferred Method The recommended method of engine ignition timing is with a dial indicator and a timing light having a self contained battery This method is considered the most convenient means of determining piston position in respect to true dead center Time the engine as fo a Remove recoil starter starter cu remove window plate if installed b Remove spark plugs disconnect igi Install a suitablo dial indicator in plug hole d Rotate dead center True de indicator scale where tl direction of motion Zero t afer to figure 5 13 Adjus 5 lows and fan belt pulley ition at coupler 0 No 1 cylinder spark to locate No 1 piston posit d center is that p pointer begi ion at true top paint on the ns to reverse dial indicator at true No inder breaker point p io 0 014 inch This point set red ignition wiring onnecl one lead of a timing light to the red wire at coupler and the other lead to ground flywheel until pointer of dial indicator reaches 15 inch betore true top dead center At this instant the ight should go out to indicate breaker points just starting to open necessary adjust ignition coil plate to the right orto the eft until the light goes out Secure ignition coll plate in his position recheck piston travel 10 verify timing accuracy NOTE If c
13. During engine operation a cam mounted on the flywheel opens and closes the breaker points in sequence condenser wired in parallel across each set of breaker points protects the points from damage caused by self inducted electrical surges in the primary coil Lighting and battery charging coils see paragraph 2 5 are mounted on the magneto coil plate The coils produce the electrical power required to operate a 12 volt lighting system and to charge the battery used with electric started engines Low tension primary wires leading from the magneto are encased in a protective cover and routed through a grommet located in the fan cover case to the ignition coupler on the fan cover 2 3 2 1 Sawafuji Ignition See Figure 2 2 The magneto used with model 3405 SAWAFUJI ignition systems has one low tension generating coil Each end of the coil isconnected in parallel to the primary of one ignition coil and one breaker point set The condensers and breaker point 2 2 sets are grounded to the magneto frame through a common ground 2 3 2 2 Kokusan Ignition See Figure 2 3 The magneto used with model 340E 340G and 400 KOKUSAN ignition systems has two low tension generating coils One end of each coil isgrounded to the magneto frame The other end of the coil connects in parallel to the breaker point set and the primary of one ignition coil 2 3 3 Operation See Figures 2 2 and 2 3 The ignition switch is connected in parallel wi
14. Piston ring grooves piston crowns cylinder heads Use the proper groove cleaning too for cleaning piston ring grooves Normal cleaning methods should be suffi cient for cleaning piston crowns and cylinder heads c Spark plug holes and exhaust ports Carefully remove heavy carbon deposits from these areas using soft metal non ferrous scraper Use a spark plug tap to clean threads CAUTION Do not scrape down to base metal surfaces when removing heavy carbon deposits Exerciso care while cleaning spark plug holes to prevent damage to the threaded area d Magneto Thoroughly dryclean the magneto using compressed air or suitable cleaning materials Ensure no moisture or oily film remains after cleaning co pecial instructions 3 3 2 Inspection 3 3 3 General a After disassembly clean all parts in accordance with paragraph 3 3 1 Inspect all parts for obvious damage wear cracks and evidence of corrosion attaching hard ware and attachment holes for wear and condition of threads If it is necessary to dress the threads use suitable ihread cleaning tools Repair or replace damaged parts and any parts that fail 10 meet applicable specifications Refer 10 Section IV Repair and Replacement b Perform additional inspections as detailed in paregraphs 3 3 4 to 3 3 13 N 3 4 Spark Plugs Inspection and Adjustment Inspect spark plugs for general condition cracked or broken insulators and burned electro
15. Spade Connector Spade Connector Terminal Connector STATOR ASSEMBLY SAWAFUJI IGNITION 4 7 Stator Assembly Coll Plate Low Tension Generating Coil Lighting Coil Condenser Red Condenser White Point Set Oil Felt amp Holder Protector Coupler 11 12 13 14 15 16 17 18 19 20 FIG 4 6 KOKUSAN IGNITION Washer Screw Spring Washer Washer Screw Spring Washer Washer Screw Screw Screw 48 21 22 23 25 26 27 28 Spade Connector 30 31 32 Screw Spring Washer Bolt Ignition Coil Attaching Bolt Coil Plate Attaching Washer Primary Ignition Coil Clamp Spade Connector Bracket Coupler Rubber Bushing Terminal Connector E Colla Crankshaft ass y 8 Piston ring 1 Ball bearing 9 Piston ring 2 Dil seal 10 Needle bearing Dil seal 11 Washer Piston note inscribed arrow 12 Spring washer Piston pin 13 Nut Circlip 14 Woodruff key FIGURE 4 7 PISTON AND CRANKSHAFT ASSEMBLY Fig 4 8 Oil seals identification 4 9 4 6 2 Condensersand Oil Felt Pads NOTE Removal and installation procedure is applicable to bath condensers 4 6 2 1 Removal Loosen electrical terminal connector 28 and disconnect primary wire at contact breaker point set 7 Unsolder condenser wires at terminal on low tension generation coil 3 and at connector on engine body c Remove retaining screw 15 and washer 16
16. breaker point set 7 Disconnect primary wire b Remove retaining screw 18 lockwasher 16 and washer 17 securing contact breaker points to coil plate 2 Remove breaker point set 4 6 1 2 Installation a Apply a light film of Lubriplate or equivalent to pivot shaft b Reverse removal procedure CAUTION Ensure no lubricant gets on breaker points wing installation Contaminated points will irn during engine operation c Adjust points to specified Refer to Section V Paragraph 5 4 3 d Flywheel assembly with ring gear Flywheel assembly less ring gear Snap ring Cam Washer Governor Spring 2 Governor weight 2 Lug spring to governor weight attaching FIGURE 4 4 FLYWHEEL ASSEMBL Flywheel 10 Ring governor weight attaching 11 Screw lug plate to flywheel attaching 12 Spring washer 13 Ring gear 14 Bolt ring gear 15 Spring washer 16 Window plate Y MAGNETO 340 3406 400 46 Stator assembly Coil Plate Primary Ignition Coil Lighting coil Condenser White Condenser Red Point Set Holder Protector FIG 4 5 10 Coupler 11 Washer 12 Screw 13 Spring washer 14 Washer 15 Screw 16 Spring washer 17 Washer 18 Screw 18 20 21 22 23 24 25 26 27 28 Screw Spring Washer Screw Washer E Ring Bracket Coupler Rubber Bushing
17. circuits In addition the separate lighting and battery charging coils as paragraph 2 5 2 1 have been changed to a single center tapped coil The ends have been terminated in two yellow wires and the internally center tapped ground connection has been extended by a brown wire to the terminal block This brown wire may be disconnected provided a satisfactory ground is maintained between the lighting circuits and the engine The coil is rated at a nominal 12 volt 75 watt maximum and can be connected to meet the various electrical configura tions 1 ONE HEADLAMP 12 V35W ONE TAIL LAMP 12V3W See Figure 2 7 A ballast resistor rated at 5 3 ohms 40 watts must be connected in parallel with the headlamp to prevent lamp burn out It will be noted from Figure 2 7 that an alternative resistor at 7 ohms 40 watts will raise the operating voltage across the lamp to give a better light at the cost of reduced lamp life 2 4 340 5 4005 6 Fig 2 5 340 E 400 LIGHTING SWITCH YELLOW A HEADLAMP COUPLER B POLE COW RECTIFER l 8 POLE 94 COUPLER 8 POLE C C W RECTIFIER LIGHTING SWITCH 12 VOLT BATTERY HEADLAMP x Figure 2 6 2 Two Headlamps 12V35W Two Tail Lamps 12V 3W See Figure 2 8 The head and tail lamps are connected in parallel across one yellow wire and ground through the lighting switch and the ballast resistor
18. equally to the Denso Ignition System 2 2 INSERT PAGE MARCH 1971 2 5 2 4 Denso Lighting System for CCW 440 CCW 440 Engines are equipped with six terminal ignition couplers similar to later models of the other engines See 2 5 2 2 Typical lighting circuit curves for the Denso Ignition System are included on insert page 2 10 A C I y 5 RED RED EC gt mol MO _ L T mo COLL 2 IGNITION 7 _SWITCH 2 CI 5 POINT 5 1 7 2 cA lt WHITE WHITE 2 38 r x Fig 2 2 Pes 28 SAWAEUJI MAGNETO _ COUPLER 340SONLY 6or8 POLE SP PA gt x a L T CONDENSER Ed COIL EO 88 02 gt n MEN TONTTION A 1 2 ONDENSER gt Fig 2 3 KOKUSAN MAGNETO Waa 3406 COUPLER 23 400 S G E 6or8 POLE PARK PLUG C COIL IGNITION COIL COIL GNITION COIL UL gt COIL IGNITION OIL engine Overheating of the engine can cause distortion of the cylinder and cylinder head seizing and burning of pistons breaking of cylinder flanges and studs etc In addition prolonged detonation may lead into pre ignition of the charge and even more serious consequences to the engine It is essentia
19. friction plate returnspring rope comes out but return spring action Replace spring as required pawls don t engage 2 Defective pawls 2 Check for broken or bent pawls Replace pawls as required Manual starter rope 1 Recoil spring broken or bent 1 Replace spring doesn t return 2 Pulley housing warped or bent 2 Replace housing 3 Starting pulley worn 3 Replace pulley Electric starter 1 Loose electrical connections Retighten connections 1 inoperative 2 Poorground 2 Secure ground connection 3 Faulty battery or circuits 3 Check recharge or replace 4 Faulty electric starter battery 4 Check starter solenoid Hepair or replace 5 Inspect starter motor for evidence of moisture and broken or worn brushes Dry out as necessary Replace brushes as required 6 Check starter switch Replace if required 7 Check harness or connector for broken wire Repair or replace Hard to start 1 Carburetor adjustments too 1 Adjust carburetor Refer or won t start lean not allowing enough gas to Manufacturer s Specifications to engine 2 Inoperative diaphragm or flapper 2 Refer to Manufacturer s valve Specifications 3 Engine not being choked to start 3 Ensure choke is fully closed 4 Spark plugs improperly gapped 4 Remove plugs Clean adjust or dirty or broken install new plugs 5 Magneto breaker points improperly 5 Clean adjust or replace points gapped or dirty 6 Head gasket blown or leaking 6 Replac
20. recoil starter and starter pulley See Section IH Para 3 2 1dand 3 2 1h Lubricate through breakerpoint access hole Remove flywheel See Para 3 2 1j Remove snap ring Lift out cam Replace cam and snap ring See Section IV Para 4 4 SECTION ffl DISASSEMBLY CLEANING AND INSPECTION 31 PREPARATION FOR DISASSEMBLY a Remove muffler and exhaust pipe as applicable Dis connect electrical wiring and controls Remove engine mounting bolts place engine on a suitable workbench Thoroughly clean exterior surfaces of engine using suitable cleaning solvent 3 2 DISASSEMBLY NOTE To preven loss and expedite reassembly procedures keep attaching hardware with each part as it is removed 3 2 1 Disassemble the engine as follows b C d Disconnect spark plug wires at spark plugs Remove plugs Remove the ten bolts securing cylinder cover to engine body Remove cover See Figure 3 1 Remove the four hold down nuts washers and lock washers securing intake and exhaust manifolds to cylin ders Remove manifolds Remove intake manifold with car buretor attached Remove carburetor if it requires servic ing Refer to applicable carburetor manufacturer s specifications Remove insulators from intake side Discard gaskets gure 3 2 emove the four bolts securing recoil starter to fan cover emove starter to expose starter cup and fan belt pulley gure 3 3 sconnect coupler attache
21. stroke engine oil See Table 2 2 20 1 at normal operating conditions Left hand standard configuration see toward the power take off end of the engine 60 Ibs 1380 23 42 1680 23 mm 28 mm 67 1 1 16 35 8 1 81 1 Sawafuji Kokusan Sawafuji 37 ohms 15 8 35 K ohms 15 1 75 2 25 amps 8 mm 500 RPM 15 mm 5 500 RPM 5 For Models G amp E see Kokusan Data under CCW 340 Ser 39 REPLACEMENT PAGE MARCH 1971 CCW 340 SER 3900000 3999999 Two stroke Two 339 20 9 cu in 60 mm 2 36 in 60 mm 2 36 in 8 2 28 BHP 6500 rpm 22 4 Ibs ft at 6000 rpm 400 gr ps h 0 88 Ib ps h Auto advanced flywheel ignition with lighting coil 12V 75W 0 3 to 0 4 mm 012 to 016 in BTDC 160 023 BTDC on Piston NGK B 8H or equivalent 0 5 to 0 6 M M 0 020 to 0 024 in Rewind starter with emergency starting pulley or electric starter output 0 5 kw Tillotson HR or equivalent Mixture gasoline of known brand and special air cooled two stroke engine oil See Table 2 2 20 1 at normal operating conditions Left hand standard configuration see toward the power take off end of the engine 60 Ibs 1540 25 mm 45 mm 1680 23mm 36 mm 66 mm 1 1 16 3 10 181 1 Kokusan Kokusan Kokusan 1 65 ohms 10 5 2 K ohms 10 1 5 1 75 amps 9 mm 500 RPM 16 mm 5 500 RPM TABLE 1 1 SPECIFICATION Cycle Number o
22. when put to full throttle Engine runs by using choke at high speed C wo irt behind needle and seat gh speed iet obstructed let lever set too low hoke partly closed lencer obstructed uel pump not supplying enough uel due to 1 Punctured diaphragm 2 Flapper valves distorted 5 Fuel line obstructed Not enough oil in gas Breaker points improperly gapped or dirty Engine improperly timed High speed needle set too lean Dirt behind needle and seat 2 18 8 9 10 11 1 Remove fuel line Clear obstruction Replace line Refuel using specified fuel oil mixture Adjust clean or install new points Re time engine to specifications amp 2 Adjust carburetor Hefer to Manufacturer s Specifications TABLE 2 1 TROUBLE SHOOTING CHART 3 Fuel line obstructed 3 Remove line clear obstruction repiace line 4 Inoperative fuel pump 4 Refer to Manufacturer s Specifications No power under heavy 1 Magneto breaker points improperly 1 Clean adjust or install new load gapped or dirty points 2 Ignition timing too far advanced 2 Adjust timing 3 Magneto coil plate loose 3 Check magneto and secure coil plate 4 Faulty carburetion 4 Refer to Manufacturer s Specifications Cranks over extremely 1 Scored piston due to 1 Replace faulty piston easy on one or both 1 No
23. 0 40 40 RPM x 00 5 RPM 100 30 20 O 161 HOHVIN 39Vd 1835 INSERT PAGE MARCH 1971 CENTRE TAP LIGHTING COIL CCW 440 DENSO IGNITION 301 15 SWITCH OMITTED TO SIMPLIFY CIRCUIT NOTE sas aaa sss i 4 o RPM O O IN IGNITION SWITCH IGNITION Colts TO POINTS HEAD
24. 02 29 57 Cubic Centimeters Kilograms kg 2 205 Pounds Pounds 4536 Kilograms Grams g 03527 Ounces Ounces 07 28 35 Grams Metric Horsepower ps 1 014 bhp Brake horsepower bhp 2859 ps Kilogram meter kg m 7 235 Foot pounds Foot pounds ft Ibs 1383 kg m Square millimeters sq mm 0 00155 sg in Square inches 645 2 59 mm TABLE 5 4 LIST OF APPROVED CARBURETORS CCW Model 340 340 340 340 400 400 400 400 Carburetor Manufacturer Walbro Tillotson Diaphragm Tillotson Diaphragm Bendix Zenith Float Chamber Tillotson Diaphragm Tillotson Diaphragm Walbro Diaphragm Bendix Diaphragm Not Required Model WR 6 HR92 ROSA 1408 5 013586 R101A HR100A WR 6 16Y 10 013599 Fuel Return Yes No Yes No Yes No Yes Yes
25. 5 watts One Taillamp 12 volt watts 2 8 2 8 LIGHTING SYSTEM MANUAL START Engine Serial Numbers 340 2903614 400 2809570 and subsequent Two Headlamps 12 volt 35 watts Two Taillamps 12 volt watts 2 9 2 9 LIGHTING SYSTEM ELECTRIC START Engine Serial Numbers 340 2903614 400 2809570 and subsequent One or two head and tail lamps Battery charging 2 10 2 9A LIGHTING SYSTEM MANUAL START Model 440 engines One Headlamp One Taillamp 2 10A 298 LIGHTING SYSTEM MANUAL START Model 440 engines Two Headlamps Two Taillamps 2 10B 2 9C LIGHTING SYSTEM ELECTRIC START Model 440 engines 2 10C 2 10 TYPICAL WIRING SCHEMATIC 8 POLE CONNECTOR MANUAL START 2 11 2 14 TYPICAL WIRING SCHEMATIC 8 POLE CONNECTOR ELECTRIC START 2 12 2 12 TYPICAL WIRING SCHEMATIC 340 s ONLY 6 POLE CONNECTOR MANUAL START 2 13 2 12A TYPICAL WIRING SCHEMATIC 340 G E 6 POLE CONNECTOR MANUAL START 2 14 2 13 TYPICAL WIRING SCHEMATIC 6 POLE CONNECTOR ELECTRIC START 2 15 3 1 CYLINDER COVER REMOVED 3 2 REPLACEMENT PAGE MARCH 1971 LIST OF ILLUSTRATIONS FIGURE NUMBER TITLE PAGE 3 2 INTAKE AND EXHAUST MANIFOLDS REMOVED 3 2 33 RECOIL STARTER AND HIGH TENSION COILS REMOVED 3 2 34 STARTER CUP AND FAN BELT PULLEY
26. 8 9 inner half 10 of pulley and spacer 11 from shaft Tap lightly on end of fan shaft to remove fan 16 from fan iner bearing d 15 should remain fan shaft assembly and be removed by sliding it off the shaft To remove outer bearing 12 turn the case over use a suitable soft drift to tap bearing out of retainer Remove spacer 13 It is not necessary to remove snap ring 14 unless it is found defective Use suitable removal tool to remove snap ring e Clean all parts except bearings using suitable cleaning solvent Wipe bearings clean using clean cloth moistened with cleaning solvent Thoroughly dry all parts after cleaning 4 2 2 Assembly a Replace defective parts b Install snap ring 14 if it has been removed Install outer bearing 12 Turn case over install spacer 13 and inner bearing 15 Ensure bearings are properly seated with no evidence of binding 1f necessary use a soft steel drift 10 tap bearings into position Ensure that no dirt or foreign material enters bearings d Reverse disassembly steps a to Tighten retaining nut securely using lock tool No 43 0792 50 Check fan for proper operation 4 1 4 3 RECOIL STARTER See Figure 4 2 4 3 1 Disassembly a Untie the knot in the rope at rope handle 15 Remove handle and allow the rope to recoil slowly into the case 12 Unscrew and remove rope guide 13
27. 99999 Two stroke Two 440 cc 26 6 cu in 60 mm 2 36 in 68 mm 2 68 in 7 8 37 BHP 6500 rpm 29 8 Ibs ft at 5750 rpm 400 gr ps h 0 88 Ib ps h Auto advanced flywheel ignition with lighting coil 12V 75W 0 3 to 0 4 mm 012 to 016 in 230 89 015 BTDC on Piston NGK B 8H or equivalent 0 5 to 0 6 M M 0 020 to 0 024 in Rewind starter with emergency starting pulley or electric starter output 0 5 kw Tillotson HD or equivalent Mixture gasoline of known brand and special air cooled two stroke engine oil See Table 2 2 20 1 at normal operating conditions Left hand standard configuration see toward the power take off end of the engine 60 Ibs 1549 26 mm 48 mm 1880 23 mm 43 66 mm 1 23 7 10 2 23 1 Denso Denso 37 ohms 10 8 35 K ohms 1596 1 75 2 25 amps 8 2500 RPM 15 mm 5 500 RPM SECTION 1 OPERATION AND SERVICE INSTRUCTIONS 2 1 PRINCIPLES OPERATION 1 To induce a mixture of fuel and air into the crankcase viathe carburetor 2 To compress the charge in the combustion chamber d The second stroke of the piston from T D C to B D C also has two functions 1 To uncover the exhaust ports and allow the burned gases to escape 2 To compress the fuel mixture in the crankcase and transfer it through the two transfer ducts to the combustion chamber a CCW two strokeengine is designed to complete in one revolution or two
28. Apply light film of Lubriplate or equivalent to spring c Secure case open side up in bench vise d fie a knot at one end of the rope Secure knotted end around center hub of reel 10 Pull rope taut and wind entire rope around reel in an anti clockwise direction until the free end protrudes through the notched section of the reel e Apply a light film of Lubriplate or equivalent to center hub of case and install the reel Push down and rotate CON Fan cover Retaining nut Lockwasher Plain washer Duter pulley Spacer Spacer FIGURE 4 1 9 Spacer 10 Inner pulley 11 Spacer 12 Outer bearing 13 Spacer 14 Snap ring 15 Inner bearing 16 Fan FAN COVER ASSEMBLY 4 2 15 1 Starter pulley 12 Case 2 Retaining nut 13 Rope guide 3 Lockwasher 14 Rope 4 Flatwasher 15 Handle 5 Friction plate 16 End piece 6 Pawl each 3 17 Bolt starter to fan cover 7 Friction plate return spring attaching 8 Spring 18 Lockwasher 9 Cup washer 19 Flatwasher 10 Reel 20 Bolt starter pulley to fly 11 Main spring wheel attaching 21 Lockwasher 22 Slot return spring retaining 23 Hook main spring retaining FIGURE 4 2 RECOIL STARTER ASSEMBLY 453 Flywheel assembly Snap ring Cam Snap ring Washer Governor weight Governor spring FIGURE 4 3 8 Lug plate 9 Flywheel Screw lug plate attachi
29. FLYWHEEL PULLER 43 0798 40 FLYWHEEL LOCK 43 0792 50 FANLOCK TABLE 1 1 SPECIFICATION Cycle Number of cylinders Displacement Stroke Bore Compression ratio Rating Maximum torque Specific fuel consumption under full load Ignition system Contact breaker gap Ignition timing setting when fully advanced Static timing setting BTDC Spark Plug Spark plug gap Starter system Carburetor Fuel Mixture ratio Rotation direction of engine Weight Inlet port timing height width Exhaust port timing height width Piston height Piston ring chromium plate top Piston ring gray cast iron bottom Cylinder head volume Cooling fan blades ratio Magneto make 3405 only 340 GE IGNITION COILS 3405 Resistance primary Resistance secondary Current rating Spark in free air three needle gap TECHNICAL DATA CCW 340 MODELS CCW 340 SER 2900000 2999999 Two stroke Two 339 cc 20 9 cu in 60 mm 2 36 in 60 mm 2 36 in 8 5 25 BHP at 5800 rpm 23 Ibs ft at 5250 rpm 400 gr ps h 0 88 Auto advanced flywheel ignition with lighting coil 12V 75W 0 3 to 0 4 mm 012t0 016in 230 80 015 on Piston NGK B 8H or equivalent 0 5 to 0 6 mm 0 020 to 0 024 in Rewind starter with emergency starting pulley or electric starter output 0 5 kw Tillotson HR or equivalent Mixture gasoline of known brand and special air cooled two
30. Fan Belt Pulley See Figure freedom of movement with no evidence of binding Lock 5 10 the flywheel using CCW Tool 43 0798 40 install flat a Install and secure fan cover to fan cover case using four 8 x washer lockwasher and nut Tighten nut to 40 50 pounds 35 bolts plain washers and lockwashers Secure ignition feet maximum torque Set timing to proper specifications terminal coupler and bracket using two Phillips head Refer to paragraph 5 4 4 Screws Fan belt pulley Fig 5 10 Fancover Starter Fig 8 11 High Tension Ignition Installed Cup and Fan belt pulley installed Fig 5 12 Recoil Starter Installed 5 6 f Va window plate was removed during disassembly replace it behind fen pulley with a lip facing outward install and secure fan pulley and starter cup to three 4 x 22 bolis and lockwashers Install fan us id adjust to proper tension Refer to Section 1282 5 2 8 Electric Starter if so equipped a Inst ant N secure electric starter to hold down studs at covercase Secure to crankcase using two 8 x 20 bolts wast id fockwashers 5 2 9 Ignition Coils Testing and installation can be tested on a a Mere 0 or other arable analyzer See Table 1 1 for specifications needle air gap ester may al also be used See Table 1 1 12 volt battery will be required on the older imodel of Merc O Tronic anal
31. G E 2903614 and Model 400 S G E 2809570 and subsequent 2 4 2 5 2 3 Model 3408 only Engines with serial numbers 2903614 amp subsequent See fig 2 12 2 7 2 5 2 4 Lighting System Denso 440 2 2A 2 6 PERIODIC SERVICING 2 7 2 6 1 Spark Plugs 2 7 2 6 2 Fan Belt 2 7 2 63 Trouble Shooting 2 7 2 7 OPERATING INSTRUCTIONS 2 19 2 7 2 Starting the Engine 2 19 27 21 Starting with recoil starter 2 19 2 7 2 2 Starting with electric starter 2 19 2 7 3 Stopping the Engine 2 19 2 8 Lubrication 2 19 DISASSEMBLY CLEANING AND INSPECTION 3 1 3 1 PREPARATION FOR DISASSEMBLY 3 2 DISASSEMBLY 3 3 CLEANING AND INSPECTION 3 3 1 Cleaning 3 3 2 Inspection 3 3 3 General 3 3 4 Spark Plugs 3 3 5 Fan Cover 3 3 6 Recoil Starter 3 3 7 Electric Starter 3 3 8 Magneto Assembly SECTION PAGE 3 3 9 Flywheel Assembly 3 9 3 3 10 Cylinder Heads and Cylinders 3 9 3 3 11 Pistons Pins and Rings 3 9 3 3 12 Crankshaft and Connecting Rods 3 9 3 313 Crankcase 3 9
32. LAMP 00000 LIGHTING COUPLER c CANADIAN CURTISS WRIGHT LTD re TORONTO ONTARIO B CCW ENGINE a APPROVED BY ik MANUAL START x TYPICAL B Pore WIRING DIAGRAM DATE med c ENGINE 2 COUPLER VIEW FRON 6 BLUE ANGULAR WHITE DRAWING NUMBER 340 S G FIGURE 2 10 40056 Nowa 1410 IGNITION SWITCH YO IGNITION COILS TO POINTS SOLENOID SWITCH STARTING g 5 92 r 1 4 1 I o o a o A B B HER DLAMP LIGHTING COIL IN O T 75 AMP 12 VOLT BATTERY bee eee 1 C C Ww RECTIFER 003 0 Q 43 0710 00 COUPLER ENGINE CANADIAN CURTISS WRIGHT LTD COUPLE VIEW E Ron RECO TORONTO ONTARIO WHITE 2 RED DECIMAL SCALE CCW ENGINE APPROVED BY ELECTRIC START POLE WIRING DIAGRAM DRAWING NUMBER 340 FIGURE 2 11 400 PICAL DATE RED 7 4 ANGULAR Nov 2 1410 IGNITION SWITCH IGNITIONCOILS HEADLAMP TO POINTS gt LIGHTING ena CANADIAN CURTISS WRIGHT LTD NOTED TORONTO mu me g 34 05 ONLY MANUAL START AL 2 PO ONLY FIGURE 2 2 DATE Nov 16 1370 ME mE IGNITION SWITCH 4 0 WT 5 ern TO IGNITION
33. Part No 43 0792 50 b Remove outer pulley Remove spacer s as required to achieve proper tension Install outer pulley plain washer lockwasher and nut Ensure belt is properly engaged between pulley halves Tighten nut securely NOTE Retain surplus spacer s for use when a new belt is to be installed 2 6 3 Troubleshooting Table 2 1 lists probable causes of engine malfunction and remedial action required to correct faults For spark plug breaker points and engine timing specifications refer to Technical Information Table 1 1 32 nora 1 2 ttti X dU i HH d n ESTE IL Tb x pa gt 4 E HEHEH HENE iban i 1 quu ming i f ig Manang Ha 1 di 444 s i 444 Hr HE HEHIHH H pan 3 sum T FEE 4 HHH d 4 n Tr Hir 4 ttt iu i ct eens t I T saa dem
34. SE AND FLYWHEEL INSTALLED 5 5 5 10 FAN COVER STARTER CUP AND FANBELT PULLEY INSTALLED 5 6 5 11 HIGH TENSION IGNITION INSTALLED 5 6 5 12 RECOIL STARTER INSTALLED 5 6 5 13 ADJUSTING CONTACT BREAKER POINTS 5 8 5 14 ADJUSTING ENGINE IGNITION TIMING 5 9 LIST OF TABLES TABLE NUMBER 131 TECHNICAL DATA 2 1 TROUBLESHOOTING CHART 2 2 LUBRICATION CHART 3 1 FITS AND TOLERANCES 5 1 CRANK VERSUS PISTON ANGLE 5 2 TORQUE SPECIFICATIONS 53 METRIC LINEAR CONVERSION FORMULAS 54 LIST OF APPROVED CARBURETORS 5 10 PAGE 1971 INTRODUCTION AND TECHNICAL DATA 1 1 INTRODUCTION 1 2 This manual contains instructions for the operation Service and repair of Canadian Curtiss Wright CCW 340 CCW 400 and CCW 440 two cycle engines 1 3 The Model CCW 340 400 440 engine Figure 1 1 One illustration is used since the three engines similar in external appearance These engines are designed for use in various snowmobile configurations and are suitable for use in Terrain Vehicles or similar applications is shown in 1 4 The instructions detail the procedures and tools re quired to ensure efficient operation servicing and repair of the engine ar d component parts Refer to Parts Catalogue for tool cross reference Engine nuts engine moun power ta
35. TECHNICAL SERVICE MANUAL OPERATION SERVICE AND REPAIR of C C W ENGINES Models C C W 340 C C W 400 C C W 440 MARCH 1971 PRINTED IN CANADA CANADIAN CURTISS WRIGHT LIMITED 500 CARLINGVIEW DRIVE REXDALE ONTARIO PHONE 677 3930 TELEX 02 29647 SECTION 1 REPLACEMENT PAGE 1971 TABLE OF CONTENTS PAGE INTRODUCTION AND TECHNICAL DATA 1 1 1 1 Introduction 1 1 1 6 Model Designation 1 1 1 8 Technical Data 1 1 1 9 Tools Special amp Standard Requirement 1 1 ILLUSTRATION OF SPECIAL TOOLS 1 3 OPERATION AND SERVICE INSTRUCTIONS 2 1 2 1 Principles of Operation 2 1 2 2 Sequence of Operation 2 1 2 3 Ignition Systems 2 2 2 3 1 General 2 2 2 3 2 Description 2 2 2 3 2 1 Sawafuji Ignition Magneto 2 2 2 3 2 2 Kokusan Ignition Magneto 2 2 2 3 2 3 Denso Ignition Magneto 2 2 2 3 3 Operation 2 2 2 4 Detonation Pre Ignition 2 2 2 4 4 Pre lgnition 2 4 2 5 LIGHTING SYSTEMS 2 4 2 5 2 Operation of Lighting Systems 2 4 2 5 2 4 Engines previous to Serial Numbers Mode 340 2903614 and Model 400 2809570 2 4 2 5 2 2 Engines Serial Numbers Model 340
36. awls should move inward c Inspect handle and rope guide for general condition and security of attachment 3 3 7 Electric Starter if installed a Inspect drive shaft and spring for condition smooth Operation and security Lubricate in accordance with Lubrication Chart Table 2 2 NOTE Disassembly or repair of electric starters should be performed by authorized dealers only Replace defective starters if overhaul facilities are not avail able 3 3 8 Magneto Assembly Inspect coil plate for damage and security b Inspect low tension generation coil s and lighting coils for general condition and security c Inspect contact breaker points and condensers for condi tion breaker points for wear burning or pitting Service able points appear a greyish frosty color If points are in Piston Pin Fig 3 11 Removing pistons Connecting rods Crankshaft Roller bearings Fig 3 12 Upper Crankcase half removed 3 8 4 serviceable condition the condenser can be considered serviceable inspect oil felt pads for condition and security lubricate in accordance with Lubrication Chart Table 2 2 Inspect all electrical connections for security insulation for chafing and deterioration 3 3 9 Flywheel Assembly a Inspect cam governor weight s and spring s for general condition and security cam for wear particularly at point of contact with governor weighis Check flywheel taper
37. ble instrument should activate to indicate No 1 cylinder breaker points just starting to open If necessary adjust ignition coil plate to the right or to the left until the correct indication is given Secure coil plate in this position Recheck timing to verify NOTE If coil plate cannot be adjusted ehough to accurately set No 1 cylinder timing recheck breaker point gap Gap may be re adjusted to 0 014 002 inch to obtain desired timing sequence e Refer to Figure 5 13 Adjust No 2 cylinder contact breaker point gap to 0 014 inch This point set has red ignition wiring Connect one lead of timing light or suitable instrument to the red wire at coupler and the other lead to ground f Rotate flywheel 1800 to the opposite set of reference marks Adjust flywheel until No 2 piston is approaching top dead center and the nearest 80 reference line is aligned with the zero reference line on fan cover At this instant the timing light should go out or suitable instrument should activate to indicate No 2 cylinder breaker points just starting to open If necessary breaker points be re adjusted to 0 014 002 inch to obtain desired timing sequence Recheck timing to verify accuracy g Replace window plate starter cup fan belt pulley and recoil starter h Replace spark plugs check engine for proper operation i Using a stroboscope check ignition timing setting auto advance mechanism when fully advan
38. c timing setting BTDC Spark Plug Spark plug gap Starter system Carburetor Fuel Mixture ratio Rotation direction of engine Weight Inlet port timing height width Exhaust port timing height width Piston height Piston ring chromium plate top Piston ring gray cast iron bottom Cylinder head volume Cooling fan blades ratio MAGNETO IGNITION COILS Resistance primary Hesistance secondary Current rating Spark in free air three needle gap TECHNICAL DATA CCW 440 MODELS CCW 440 SER 2500000 2599999 Two stroke Two 440 cc 26 6 cu in 60 mm 2 36 in 68 mm 2 68 in 7 8 33 BHP at 6000 rpm 30 5 Ibs ft at 6000 rpm 400 gr ps h 0 88 Ib ps h Auto advanced flywheel ignition with lighting coil 12V 75W 0 3 to 0 4 mm 012 to 016 in 230 BIDC 89 015 BTDC on Piston B 8H or equivalent 0 5 to 0 6 mm 0 020 to 0 024 in Rewind starter with emergency startirig pulley or electric starter output 0 5 kw Tillotson HR or equivalent Mixture gasoline of known brand and special air cooled two stroke engine oil See Table 2 2 20 1 at normal operating conditions Left hand standard configuration see toward the power take off end of the engine 60 Ibs 1500 25 mm 46 mm 1689 23 41 mm 66 mm 1 1 22 8 10 1 81 1 Denso Denso 37 ohms 10 8 35 K ohms 15 1 75 2 25 amps 9 mm G 500 RPM 15 mm 5 500 RPM INSERT PAGE MARCH 1971 CCW 440 SER 3500000 35
39. ced in accordance with Specifications Table 1 1 5 4 4 3 Crankshaft Angle Versus Piston Travel Table 5 1 lists piston position relative to crank angle zero reference Flywheel Reference lin Fig 5 14 Setting Engine Ignition Timing Alternate Method TABLE 5 1 CRANK ANGLE VERSUS PISTON TRAVEL Crank Angle Distance from Top Dead BTDC 50 0 006 6 0 008 7 0 011 8 0 015 9 0 018 10 0 023 11 0 028 12 0 033 13 0 038 14 0 044 15 0 051 16 0 058 17 0 065 18 0 073 19 0 081 20 0 089 21 0 099 22 0 108 23 0 118 24 0 129 25 0 139 26 0 150 27 0 162 28 0 174 29 0 186 30 0 198 5 9 TABLE 5 2 TOROUESPECIFICATIONS Location Type Size Lbs Ft Crankcase Screws 8mm 12 15 Cylinder Head Nuts 8mm 15 18 Cylinder 10 Crankcase Nuts 8 12 15 Flywheel to Crankshaft Nut 14 mm 45 50 Fan Pulley Nut 12mm 28 31 TABLE 5 3 METRIC LINEAR CONVERSION TABLE Multiply by to Obtain Known Unknown Millimeters mm 0 03937 Inches Inches in 25 4 illimeters Centimeters cm 3937 Inches Inches 2 54 Centimeters Kilometers km 8214 iles Miles mi 1 608 Kilometers Meters m 3 28 Feet Feet ft 3048 Meters Cubic Centimeters 06 Cubic Inches Cubic Inches cu in 16 387 Cubic Centimeters Liters 1 264 Gallons Gallons qal 3 785 Liters Liters 1 1 057 Quarts Quarts 41 946 Liters Cubic Centimeters tec 0339 Fluid Ounces Fluid ounces
40. cturer s Specifications Overheating 1 Carburetor too lean 1 amp 2 Adjust carburetor 2 Carburetor too rich Refer to Manufacturer s Specifications timing 3 Retime engine to Specifications 4 Too much carbon 4 Remove cylinder heads Clean top of pistonsand inside compression chamber Clean out exhaust port 5 Spark plug too hot 5 Install specified spark plugs 6 Air deflector not installed 6 Install air deflector 7 Air leak in manifold 7 Tighten nuts or change gaskets 8 Crankcase seal leaking 8 Fit new seal Vibrates excessively or 1 Idle or high speed carburetor 1 to 5 Adjust carburetor Refer runs rough and smokes adjustment too rich to Manufacturer sSpecifications 2 Choke not opening properly bent linkage 2 17 TABLE 2 1 3 4 5 6 7 8 9 TROUBLE SHOOTING CHART Inlet control lever too high carburetor floods Idle air bleed plugged Welch plug loose Muffler obstructed Engine secured tightly to engine support Water in gas Water in the ignition switch 6 7 8 9 Check and clear muffler Tighten engine mounting bolts Add carburetor de icer fluid as required Dry out switch using suitable de icer spray or heat Won t start kicks back and backfires No acceleration low top R P M hard to start Good spark but engine runs on one cylinder No acceleration 10165 gt N NN
41. d of crankshaft to remove flywheel Damage to the shaft or bearings may result Figure 3 6 ove the four bolts securing fan covercase 10 crank Hemove covercase Case Figure 3 7 Remove the two screws securing stator assembly to crankcase Hemove stator assembly Figure 3 8 NOTE Unless being serviced stator assembly should be stored inside flywheel to ensure retention of mag netic properties Remove the five hold down nuts securing each cylinder head to cylinder Remove cylinder heads Discard cylinder head gaskets Tool 13mm box spanner NOTE Before proceeding any further check crankshaft for 1 bend and twist as follows Check for twisi Rotate engine to T D C on 1 cylinder using a dial indicator mounted on the cylinder b Install and zero a degree wheel on the crankshaft c Rotate crankshaft 1809 The piston on No 2 cylinder should be at T D C Permissable tolerance is 20 Check for bend on either end a Mount a dial indicator at the junction of the parallel and tapered sections of the shaft b Zero the indicator Rotate the crankshaft one full turn Permissable runout is 0 003 inch on one rota tion Remove the four hold down nuts securing each cylinder to crankcase Remove cylinders to expose piston and connecting rod assemblies Discard cylinder base gaskets Figure 3 10 CAUTION If disassembly is discontinued after cylinder piston removal
42. d to fan cover Remove two bolts securing coil cover to fan cover Remove cover to expose high tension coils Figure 3 3 Remove the two bolts and spacers securing high tension coils to fan cover Remove coils with spark plug wires attached Remove the two hold down nuts two attaching bolts and lockwashers securing electric starter to engine body if so equipped Remove starter Remove starter h Remove the three bolts securing starter cup fan belt pulley and window plate if installed to flywheel Pull outward and up on pulley to remove from flywheel Remove fan belt Remove the two Phillips screws securing ignition terminal coupler and bracket to fan cover and four bolts securing fan cover to fan cover case Remove fan cover to expose flywheel 3 1 j Lock the flywheel using CCW Tool Part 43 0798 40 CAUTION remove the nut lockwasher and flat washer securing flywheel to crankshaft Remove the flywheel as follows 1 Install flywheel puller to the three tapped holes in flywheel 2 Tighten the center bolt of puller to 40 pounds feet maximum 3 Using a wooden mallet or block and hammer tap each side of the flywheel alternately while maintaining the torque setting on center bolt until the flywheel is removed 1 Do not over torque center bolt on flywheel puller Excessive torque may result in break ing the puller attachment bolts 2 Do not hammer on en
43. des Guide to spark plug serviceability 1 Center electrode burned brown indicates plug is unctioning normally 2 Center electrode burned white indicates the plug is 100 low in thermal value Discard plug and install new plug specified type 3 Center electrode burned black indicates the plug is too ligh in thermal value Discard plug and install new plug of specified type b Adjust spark plug gap to 0 6 to 0 7 mm 0 023 to 0 025 in Bend the outside ground electrode only Use a spark plug wire gauge to measure the gap Discard plug if electrode is burned exeessively or if specified gap cannot be maintained c Inspect spark plug wires for condition of insulation rubber bushings for splitting or deterioration tips for security Replace defective wiros 3 3 5 Fan Covers a Inspect fins for cracks fan for blade damage freedom of movement and evidence of binding Dress out nicks or dents Replace fan if a blade is cracked or broken since the balance will be affected b Inspect fan belt for stretch fraying and deterioration 3 3 0 RecoilStarter Pull starter rope out and permit it to recoil Do let rope snap back on recoil Hope should pull out smoothly and recoil without hesitation weak or incomplete recoil indicates a defective or maladjusted main spring b Check for smooth operation of pawls When the rope is ulled out pawls should move outward when the rope recoils p
44. disassembly of flywheel assemblies should be performed by authorized dealers only The auto advance mechanism is pre set during manufac iure and should require no further adjustment inspection reveals faulty governor parts or defective magnets install a new flywheel assembly or return flywheel to overhaul facility a Remove snap ring 3 securing breaker point cam 4 to flywheel collar using a suitable snap ring removal tool Lift cam off collar Check cam and collar for scoring and wear governor weight stops for wear and security Replace defective parts 4 5 2 Assembly Apply a light film of Lubriplate or equivalent to outer surface of flywheel collar Reverse removal procedure Lubricate in accordance with Lubrication Chart Table 2 2 d Check mechanism for proper operation 4 6 STATOR ASSEMBLY SAWAFUJI MODEL 3405 See Figure 4 5 NOTE Complete disassembly of stator assemblies should be performed by authorized dealers only Normal dis assembly should be restricted to removal and replace ment of defective contact breaker point sets oil felt pads or condensers inspection reveals additional maintenance requirements install a new assembly return stator to overhaul facility 4 6 1 Contact Breaker Point sets NOTE Removal and installation procedure is applicable to both point sets 4 6 1 1 Removal a Loosen electrical terminal connector 28 securing con densor primary wire at contact
45. dition or adequate ly protected from dust dirt and other contaminants until ready for use b e Installation Reverse removal procedure and note the following a Bearings are a press fit on the crankshaft Install new bearings as follows 1 Apply a light film of lubricating oil to crankshaft and ball bearing inner race 2 Preferred Method The preferred method of installation is with the use of an arbor press Lay the new bearing on a face block having a slot or hole slightly larger than the bearing inner bore press shaft down until bearing is firmly seated 3 Alternate Method ethod of installation is with the use of a soft tube Use a suitable length of mild steel tubing accurately squared at the ends with large enough inside diameter to slip loosely over the crankshaft Start bearing on end of crankshaft Using the tube An alternate m gently tap the bearing down the shaft until bearing ts firmly seated CAUTION Prevent damage to the shaft and bearings until installation Ensure that bearing Is started true and not cocked on the shaft and that no loose metal chips are allowed to fall into bearings b Use new oil seals Oil seals are marked with an arrow indicating direction of crankshaft rotation Correct direc tion of arrow rotation is clockwise from flywheel end and anti clockwise from power take off end Refer to Figure 4 8 Ensure seal is installed with cup facing inward and arrow direct
46. e 0 Ibs 1380 26 mm 46 mm 1680 23mm 38 mm 67 mm 1 1 17 0 8 1 81 1 Kokusan Kokusan 1 65 ohms 1096 52 K ohms 10 1 5 1 75 amps 9 mm 500 RPM 16 mm 5 500 RPM INSERT PAGE MARCH 1971 CCW 400 SER 3800000 3899999 Two stroke Two 398 cc 24 3 60 mm 2 36 in 60 mm 2 56 in 8 2 33 BHP 6500 rpm 26 7 Ibs ft at 6000 rpm 400 gr ps h 0 88 Ib ps h Auto advanced flywheel ignition with lighting coil 12V 75W 0 3 to 0 4 mm 012 to 016 in 239 BTDC 109 023 BTDC on Piston NGK B 8H or equivalent 0 5 to 0 6 M M 0 020 to 0 024 in Rewind starter with emergency starting pulley or electric starter output 0 5 kw Tillotson HD or equivalent Mixture gasoline of known brand and special air cooled two stroke engine oil See Table 2 2 20 1 at normal operating conditions Left hand standard configuration see toward the power take off end of the engine 60 Ibs 1460 25 mm 48 mm 1680 23 mm 40 mm 66 mm 1 1 18 2 10 2 23 1 Kokusan Kokusan 1 65 ohms 10 52 K ohms 10 1 5 1 75 amps 9 mm 500 RPM 16 mm 5 500 RPM TABLE 1 1 Number cylinders Displacement Stroke Bore Compression ratio Rating Maximum torque Specific fuel consumption under full load Ignition system Contact breaker gap Ignition timing setting when fully advanced Stati
47. e by closing off the air supply to the carburetor will be apparent that the engine cannot be stopped by switching off the ignition 2 5 LIGHTING SYSTEM 2 5 1 Vehicle lighting is provided by lighting and battery charging coils in the magneto and the necessary wiring and light switches required to operate the system 2 5 2 peration 2 5 2 1 Engines Previous to Serial Numbers Model 340 2903614 Model 400 2809570 Typical vehicle lighting circuit See Figure 2 11 Engines bearing serial numbers previous to 340 29036 14 or 400 2809570 are equipped with an eight terminal ignition coupler The lighting and battery charging circuits include two separate coil windings which produce 75 watts AC alternating current during magneto operation One coil winding supplies the power required to operate the lighting system and the other winding supplies the power required to charge a 12 volt battery for use with electric started engines MANUAL STARTED ENGINES See Figure 2 4 Single head and tail lamp 12 V 35 W 12 V 3W 8 The two wires from the battery charging coil winding are 24 blue colour Both of these wires routed to the ignition coupler The lighting coil winding is yellow in colour end is routed to the ignition coupler and the other is grounded at the magneto A headlamp and tail lamp with maximum rating of 35 watts may be installed on the vehicle The wire to operate the light switch is connected to t
48. e gasket 7 Empty gas tank or improper fuel 7 Refill tank with specified mixture fuel oil mixture See Table 1 1 8 Water in fuel system 8 Drain fuel from carburetor Add carburetor de icer es required to fuel 9 Weak coil or condenser 9 Replace faulty coil or condenser 10 Obstructed fuel system 10 Disconnect fuel lines clear obstruction Flush system Connect fuel lines 11 Air leak in crankcase or inlet 11 Check crankcase pressure system Table 3 1 12 Primary wire broken 12 Repair or replace primary wire 13 Engine not timed properly 13 Re time engine to proper specifications 14 Secondary wire not connected 14 Secure secondary wire or or spark plug protector not spark plug protector installed properly Impossible to adjust 1 Spark retarding mechanism not 1 Repair retard mechanism idle working properly 2 Pistons or rings worn 2 Replace as necessary 3 Faulty carburetor 3 Check carburetor check valve Refer to Manufacturer s Specifications 2 16 TABLE 2 1 TROUBLE SHOOTING Missing at low speed 1 carburetor idle 1 Adjust idle Refer to or won t idle smoothly adjustment Manufacturer s Specifications or slowly 2 Spark plugs improperly gapped 2 Clean adjust or install or dirty new plugs 3 Head gasket blown or leaking 3 Replace gasket 4 Loose or broken magneto wires 4 Repair or replace wires 5 Magneto breaker points 5 Adjust clean or install im
49. ed as shown in the illustration Exercise care when installing seals prevent sea damage ind leaks during engine operation CCW 440 DENSO IGNITION 4 9 STATOR ASSEMBLY Repair amp Replacement NOTE Complete disassembly of stator assemblies shouid be performed by authorized dealers only Normal disassembly should be restricted to removal and replacement of contact breaker point sets oil felt pads or condensers f inspection reveals additional maintenance requirements install a new assembly or return stator to overhaul facility 4 9 1 Contact Breaker Point Sets NOTE Removal and installation procedure is applicable to both point sets 4 9 1 1 Removal Loosen electrical terminal connector securing ignition wiring at contact breaker point set 7 Disconnect the wires Remove retaining screw 22 lockwasher 21 and washer 20 securing breaker point set to coil plate 2 Remove breaker point set 4 9 1 2 Installation a Apply a light film of Lubriplate or equivalent to pivot shaft b Reverse removal procedure INSERT PAGE MARCH 1971 CAUTION Ensure no lubricant gets on breaker points during installation Contaminated points will burn during engine operation c Adjust points to specified gap Refer to Section V Paragraph 5 4 3 4 9 2 Condensers and Oil Felt Pads NOTE Removal and installation procedure is applicable to both condensers 4 9 2 1 Removal a Loosen e
50. ensure that crankcase 15 kept covered to prevent ingress of dirt or foreign objects to crankcase exhaust manifoid Cylinder Cover 5 Intake manifold Fig 3 1 Cylinder Cover Fig 3 2 Intake and Exhaust Removed Manifolds Removed ncc Coil cover attaching coupler attaching Starter cup 2 disconnect starter 4 high tension coils f Spark plug leads Fig 3 3 Recoil starter and high tension coils removed 3 2 Fanbelt Fig 3 4 Starter cup and fan belt pulley removed Fan Cover Backing Plate Bracket coupler Fig 3 5 Fan cover removed 3 3 3 6 Removing flywheel Fig 3 6A Fig 3 7 Fan cover case removed 3 4 lt IIIIIRTIULYIsIII I Em Fig 3 8 Stator assembly removed 3 5 Cylinder heads Head gasket Fig 3 9 Cylinder heads removed ip TES 8 f inum A m Fig 3 10 Cylinders removed 3 6 Refer to Section IV Figure 4 7 Before removing pistons 5 ensure that the piston crown is marked with an arrow directed toward the exhaust port If no arrow 15 legible inscribe the piston crown accor dingly Using a suitable circlip removal 1091 remove one of the two circlips 7 securing each piston pin 6 in position Use a propane torch or cloth soaked in hot water and heat the pistons until warm to
51. f cylinders Displacement Stroke Bore Compression ratio Rating Maximum torque Specific fuel consumption under full load Ignition system Contact breaker gap Ignition timing setting when fully advanced Static timing setting BTDC Spark Plug Spark plug gap Starter system Carburetor Fuel Mixture ratio Rotation direction of engine Weight Inlet port timing height width Exhaust port timing height width Piston height Piston ring chromium plate top Piston ring gray cast iron bottom Cylinder head volume Cooling fan blades ratio MAGNETO IGNITION COILS Resistance primary Resistance secondary Current rating Spark in free air three needle gap TECHNICAL DATA CCW 400 MODELS CCW 400 SER 2800000 2899999 Two stroke Two 398 cc 24 3 cu in 60 mm 2 36 in 65 mm 2 56 in 8 5 30 BHP at 5800 rpm 27 3 Ibs ft at 5500 rpm 400 gr ps h 0 88 Ib ps h Auto advanced flywheel ignition with lighting coil 12V 75W 0 3 to 0 4 mm 012 to 016 in 230 BTDC 89 015 BTDC on Piston NGK B 8H or equivalent 0 5 to 0 6 mm 0 020 to 0 024 in Rewind starter with emergency starting pulley or electric starter output 0 5 kw Tillotson HR or equivalent ixture gasoline of known brand and special air cooled two stroko engine oil See Table 2 2 20 1 at normal operating conditions Loft hand standard configuration see toward the power take off end f the engin
52. for snug fitting When placed on crankshaft hand tight the flywheel should not wobble inspect magnets for nicks scores or burrs Use a suitable stone to smooth off high spots Inspect ring gear and teeth if installed for wear general condition and security Lubricate cam governor weight and spring in accordance with Lubrication Chart Table 2 2 3 3 10 Cylinder Headsand Cylinders a b Inspect cylinder heads and cylinders for pitting scoring and evidence of corrosion Check cylinder heads for warp or distortion as follows 1 Place cylinder head flat side down on a surface plate or suitable measuring device 2 Using a feeler gauge measure amount of distortion at point of contact between cylinder head and surface plate Take a reading at each of the five locations between cylinder head hold down studs Maximum allowable distortion at any one location 0 002 inch Check cylinders for distortion as follows 1 Install serviceable head on cylinder to be checked Do not install hold down nuts 2 Using a feeler gauge measure amount of distortion at point of contact between cylinder head and cylinder Take a reading at each of the five locations between cylinder head hold down studs Maximum allowable distortion at any one location is 0 002 inch Using a dial indicator or suitable measuring device check inside diameter of cylinders Cylinders worn beyond standard tolerances may be rebored to acc
53. he yellow terminal in the ignition coupler MANUAL STARTED ENGINES See Figure 2 6 Twin head and tail lamps 12 V 35W 12 V See drawing Number E 3408 150 Two 12 volt 35 watt headlamps are connected in series with the single yellow wire Three 12 volt 3 watt tail or speedometer lights complete the circuit in series parallel connection with a ballast resistor rated 7 ohms 40 watts A parallel circuit with a single pole double throw switch is shown connected across the head lamps In the event of alamp failure the switch can be placed in left or right position to provide a circuit to the remaining head and tail lamps N B This circuit can be omitted if not required Materials required Load resister 7 ohms 40 watts 1 SPDT Switch 5 amps 1 These items are available from Canadian Curtiss Wright Limited ELECTRIC STARTED ENGINES See Figure 2 5 b On engines equipped with an electric starter the two blue wires at the ignition coupler are plugged into a C C W rectifier part number 43 0710 00 and the AC is con verted to DC direct current The black wire is grounded From the rectifier DC is routed through a 7 5 ampere fuse to the battery Power to operate the lights is taken from the battery 2 5 2 2 Engines with Serial Numbers Model 340 G F 2903614 Model 400 S G E 2809570 and Subsequent 8 Engines bearing serial numbers as above are equipped with 8 six pole terminal coupling for the ignition and lighting
54. hold down studs with machined side facing inwards and cylinder cover attach ing brackets facing toward intake ports Power take off end REPLACEMENT PAGE MARCH 1971 c Refer to Figure 5 7 I Install the ten washers lockwashers and hold down nuts install the two long internally threaded nuts above the intake ports at location 5 Torque nuts down evenly to 15 18 foot pounds max accordance with the sequence shown in the illustration cylinder heads Fig 5 6 Installing Cylinder Heads Flywheel end i Fig 5 7 Cylinder head hold down nut torquing sequence 5 4 5 2 5 Stator Assembly See Figure 5 8 5 2 6 Fan Cover Case and Flywheel See Figure 5 9 a Install and secure stator to engine crankcase using two a Install and secure fan cover case to crankcase using four 8 Phillips head screws Position ignition wire bundle in the x 28 bolts plain washers and lockwashers recess provided and install rubber grommet b Place a Woodruff key in the slot on the crankshaft Ensure flywheel center bore and tapered end of crankshaft are free of oil or grease Align keyway and key slide flywheel Contact Breaker retainimg screws Coil Plate retainings screws Fig 5 8 Stator assembly installed Fan Cover Backing Plate Bracket coupler Fig 5 9 Fan cover backing plate and flywheel installed 5 5 on to shaft as far as it will go Rotate flywheel to ensure 5 2 7 Fancover Starter Cup and
55. is of course unnecessary 3 Electrical Start Engines See Figure 2 9 On engines equipped with an electric starter motor a full wave rectifier CCW Part No 43 0715 10 is connected to the two yellow wires at the terminal coupler and the A C output is converted to D C 7 5 amp fuse is connected to the D C output red wire and the circuit is completed via the lighting switch to charge the battery Head and tail lamps are connected across the battery terminals as shown in Figure 2 9 2 5 2 3 Model 3405 only Engines with serial numbers 2903614 amp subsequent See fig 2 12 Engines bearing serial numbers as above are equipped with Sawafuji magnetos amp six pole connectors for lighting amp ignition circuits The separate lighting and battery charging coil have been retained as per paragraph 2 5 2 1 2 6 PERIODICSERVICING 2 8 1 Spark Plugs Remove inspect clean and or adjust spark plugs at regular intervals as necessary See Section para 3 3 4 Discard excessively burnt or damaged plugs Install only specified spark plugs after adjusting to proper gap Table 1 1 2 6 2 Fan Belt Periodically check fan belt for wear fraying and proper tension properly adjusted fan belt should leave approxi mately 1 4 inch side play when flexed by hand at a point near center of belt length Adjust fan belt tension as follows a Remove 19 mm nut lockwasher and plain washer from threaded end of fan shaft using locking tool
56. ke 0 bolts and threads are metric except for the ing bolts which are 7 16 SAE coarse and the ff P T 0 end of the crankshaft which is 1 2 SAE fine 20 1 5 Carburetion data for the engine models covered in this manual is detailed under separate instructions For buretor technical requirements refer to Appendix l or to applicable manufacturer s specifications 1 6 MODEL DESIGNATION 1 7 The letters and numbers in the subject engine models designate the following CCW Manufacturer s type designation 340 400 440 Cubic centimeter displacement Manual Start Electric Starter G Geared flywheel for subsequent electric starter installation SERIAL NOS MODEL COMMENCING 18 CCW 400 1 19 CCW 340 1 Physical 25 CCW 440 1 Differences 28 CCW 400 2 See Spec Sheet 29 CCW 340 2 Page 1 4 35 CCW 440 2 38 CCW 400 3 39 CCW 340 3 NOTES a Models CCW 340 of serial nos 19 and 29 manual start version are equipped with a Sawafuji ignition system comprised of one low voltage generating coil and high voltage coils of opposite polarity b Models CCW 340 of serial nos 19 and 29 electric start and gear ring equipped 340 ser no 38 and CCW 400 all models all versions are equipped with a Kokusan ignition system comprised of two low voltage generating coils and two high voltage coils all of the same polarity c
57. l therefore that detonation should be recognized and the cause eliminated as soon as possible 2 4 3 Most of the common causes of detonation can be easily rectified 1 High compression pressures CCW 340 400 175 180 PSI cold at 500 RPM Incandescent points in the combustion chamber due to ash deposits 3 Wrong type of spark plugs See Table 1 1 Spark plug overheated due to seat washer being worn missing Incorrect ignition timing See section 5 4 4 Weak carburetor settings High ambient temperatures Over 950 Partially choked exhaust system causing high back pres sure lt gt 2 4 4 PRE IGNITION may be defined as the premature burning of the charge due to spontaneous combustion and before the specified timed ignition point by the spark plug The resultant gas expansion acting on the rising piston gen erates extreme temperatures and pressures in the combustion chamber and frequently results in broken pistons bent connecting rods twisted or bent crankshaft and damaged bearings Pre ignition is usually caused by overheating and can be readily identified by the very heavy knocking which is due to gas expansion on the rising piston It is usually preceded by detonation but certain conditions such as an under sized or choked exhaust system will cause the engine to go straight into pre ignition without detonation It is imperative that the engine should be stopped at onc
58. l2 RESISTOR _ To lt POINTS 1 6 LIGHTING AND CHARGING COIL d mess COUPLER ENGINE 5 CANADIAN CURTISS WRIGHT LTD j NOTED TORONTO ONTARIO COUPLER VIEW FACING DECIMAL SCALE 2 YELLOW CARBURETOR _ ENGINE FRACTIONAL TITLE 5 4 MANUAL START TYPICAL POLE WIRING DIAGRAM 6 WHITE ANGULAR DATE DRAWING NUMBER 340 G Nev2 110 FIGURE 2 40756 TRANSTEX 15 8500 5 67 _ IGNITION SOLENOID SWITCH 3 35 STARTING TO IGNITION COILS le v MOTOR HEADLAMP x POINTS LIGHTING AND 777777777777 gt HARGINC TU _ c 12 Vout 75 BATTERY FUSE 1 1 COW RECTIFER 0777 COUPLER 45 0715 10 s CANADIAN CURTISS WRIGHT LTD TORONTO ONTARIO ___ COUPLER VIEW C DECIMAL SCALE DRAWN BY w CARBURETOR CCW ENGINE APPROVED BY uu wwe FRACTIONAL TITLE TNPICAL WIRING DIAGRAM RED 5 gt G WHITE ANGULAR DATE DRAWING NUMBER 34 0 FIGURE 2 15 400E 18 RAN R AT TABLE 2 1 TROUBLE SHOOTING Trouble Probable Cause Remedy Manual starter 1 Lack of friction plate 1 Check
59. lectrical terminal connector at contact breaker point set 7 Disconnect the condenser lead wire b Remove retaining screw 23 and washer 21 securing condenser to coil plate 2 Remove condenser and oil felt pad if attached Check pad for condition and replace if lubricating capacity is questionable 4 9 2 2 Installation a Reverse removal procedure b Lubricate oil felt pad Refer to Lubrication Chart Table 4 10 FLYWHEEL ASSEMBLY CCW 440 See Fig 4 12 4 10 1 Disassembly NOTE Complete disassembly of flywheel assemblies should be performed by authorized dealers only The auto advance mechanism is pre set during manufacture and should require no further adjust ment If inspection reveals faulty governor parts defective magnets install a new flywheel assembly or return flywheel to overhaul facility Remove snap ring 5 and governor weight 4 to release the breaker point cam Lift cam off collar Check cam and collar for scoring and wear governor weight stop screw for wear and security Replace defective parts 4 10 2 Assembly a Apply a light film of Lubriplate or equivalent to outer surface of flywheel collar b Reverse removal procedure Lubricate in accordance with Lubrication Chart Table 2 2 d Check mechanism for proper operation INSERT PAGE MARCH 1971 SECTION V REASSEMIBLY TESTING AND ADJUSTMIENTS 5 1 GENERAL 5 1 1 Prior to reassembly check all parts for clea
60. n switch 212 Starting Adjust throttle lever as required wait approximately 30 2 7 2 1 Starting the engine using recoil starter seconds and repeat the starting procedure d After the engine has started gradually open the choke a Adjust throttle lever to approximately one half full open lever and close the throttle lever until the engine runs position smoothly at idling speed 1000 1200 rpm When the hu j gt engine is running at normal operating temperature the not be necessary to close the choke choke should remain in the fully open position Switch the ignition to the RUN position d Pull lightly on the handle of the rope until aclick is heard NOTE if the engine fails to start after repeated attempts when the pulley engaged with the flywheel and then pull refer to Trouble Shooting Chart Table 2 1 strongly on the rope Let thehandle return quickly to the original position Do not let go of the handle until the rope 2 1 3 Stopping the Engine b Close carburetor choke lever When starting a warm engine fully retracted To stop the engine close throttle switch off the ignition Do IF engine does not start repeat step d and adjust throttle not stop engine by grounding the spark plugs or disconnect lever as required until the engine starts ing spark plug wires f After the engine has started gradually open the choke ever and close throttle lever until the engi
61. nd float N A 003 Feeler gauge Piston at CCW 340 2 36 60 N A Micrometer CCW 400 2 56 65 N A CCW 440 2 67 68 N A 4 11 012 Piston Pin 007 008 Bottom of skirt 004 0047 Piston Pin 709 18 0004 Dial Indicator Piston Pin 709 18 0003 Micrometer Piston Ring No 1 083 0025 N A Feeler Gauges groove clearance 004 end clearance 004 012 Piston Ring No 2 083 0014 groove clearance 003 end clearance 004 N A 012 Tr M M 3 10 SECTION 1V REPAIR AND REPLACEMENT 41 GENERAL 4 1 1 The repair and replacement instructions detailed in this section are included to assist in the disassembly replacement of defective parts and assembly of major subassemblies It is not necessary to completely disassemble the sub assemblies unless inspection procedures reveal defects Perform only those steps necessary to gain access to the defective part s and to effect the necessary repairs 4 2 FAN COVER See figure 4 1 4 2 1 Disassembly 2 lockwasher 3 and plain washer 4 ireaded end of fan shaft Spacer 5 is permanently secured to outer pulley 6 Tool 19 mm box span 43 0792 50 NOTE tool Remove nut fram t ver Locking tool Part No 1 4 hole in pulley to take pin of locking b Remove outer half 6 of fan belt pulley spacers 7
62. ne runs 28 LUBRICATION smoothly at idling speed 1000 1200 rpm When the Lubrication chart Table 2 2 details periodic lubrication engine is running at normal operating temperature the requirements Further periodic lubrication of these engines is hoke should remain in the fully open position not required 2 19 TABLE 2 2 RecoilStarter Center hub Main spring Pawls Electric Starter drive shaft and spring if installed Contact Breaker Points oil felt pads Contact Breaker Point Cam LUBRICATION CHART Periodicity Once yearly or during overhaul Once yearly during overhaul Once yearly or during overhaul Once yearly or during overhaul The following is a list of recommended brands of two stroke engine Esso Snowtrac Veedol Snowmobile Shell Two Cycle Snowmobile Mercury 50 New Formula Quicksilver Bardahl Snowmobile 2 20 Type Method Grease law temper ature Lubriplate or equivalent by hand Grease low temper ature Lubriplate or equivalent by Tor 2 drops good quality light machine oil oil can Grease low temper ture Lubriplate or equivalent Lightly coat governor assembly and flywheel collar by hand Access Remove recail starter cover Remove friction plate See Section Para 3 2 1d and Section IV para 4 3 Remove starter See Section IH Para 3 2 18 Remove
63. ng 11 Spring washer 12 Washer 13 Screw governor stop 14 Spring washer FLYWHEEL ASSEMBLY 3405 4 4 reel in an anti clockwise direction until the hook 23 engages with the free end of main spring Tension will be felt when reel and spring are properly engaged f Rotate reol maximum of three complete turns in an nti clackwise direction Do not exceed three turns hold reel in this position and feed free end of rope through case t the rope guide hole Install rope guide Loosely knot rope 10 prevent recoil g Apply a tight film of Lubriplate or equivatent to pawls 6 and install them on the reel in the pawi rotainers Install cup washer 9 flat side down spring 8 and return spring 7 Ensure that plain end of return spring is engaged in the retaining hole in reel hub i Install friction plate 5 over reel hub Manipulate plate intil eye return spring engages and locks crosswise in retaining slot 22 Rotate friction plate until the three notches are aligned ith pawls when pawls are at the recoil position stall flatwasher 4 lockwasher 3 and nut 2 Vighten nut securely ie the temporary knot in free end of rope and install the rope handle permanent knot and fit handle securely m Check starter for proper oporation When handle is pulled uutward pawls should move outward qui gt GO 5
64. nger bolts at locations 2 3 4 and 7 Loosely tighten the four bolts at locations A then torque all bolts down evenly to 15 18 foot pounds maximum in accordance with sequence shown in the illustration 5 2 2 Pistons Piston Rings and Pins See Figure 5 3 a Lubricate piston pin needle bearing with two stroke Oilseal Retaining circlips Fig 5 1 Crankcase Lower Half 5 1 Power take off end REPLACEMENT PAGE MARCH 1971 Flywheel end Fig 5 2 Crankcase Bolt Torquing Sequence engine oil and install bearing into connecting rod small end If both piston pin retaining circlips have been removed from piston use a suitable tool and install a circlip at one piston pin bore Use a propane torch or cloth soaked in hot water and heat piston until warm to the touch 120 to 140 F Ensure that the arrow on piston crown is directed toward the exhaust port and align piston pin bore with center bore of connecting rod Lubricate piston pin and using a soft drift push pin into piston until it bottoms on the installed circlip Exercise care to prevent damage to needle bearing Install remaining circlip d 8 Install piston rings in ring grooves using a suitable ring installing tool Ensure that piston ring gap is correctly positioned at the ring groove locating pin Repeat steps to d for second piston NOTE The chromium plated ring should be installed in the top groove 5 2 3 Cylinders See Figu
65. nliness and serviceability in accordance with paragraph 3 3 5 1 2 During assembly tighten all screws bolts and nuts securely Ensure that correct torque values are applied where specified Do not overtorque 5 1 3 Use only new gaskets and seals during assembly procedure 5 1 4 During assembly lubricate all bearings and friction surfaces with new clean two stroke engine oil 5 1 5 f procedures are discontinued during assembly ensure that intake and exhaust ports spark plug holes and all other openings are covered to prevent ingress of dirt or foreign objects to cylinders and crankcase 5 2 REASSEMBLY 5 2 1 Crankcase and Crankshaft See Figure 5 1 a Place crankcase lower half on work bench with flanged fan cover end to right hand side insert the four seal retaining circlips Install the crankshaft into lower half of crankcase with externally threaded flywheel end of shaft toward right hand side See Section figure 3 12 Ensure that seal retaining circlips do not become dislodged b Apply a liberal amount of two stroke engine oil to crankshaft and bearings c Apply a good quality non hardening sealing compound evenly to sealing surfaces of both crankcase halves d Reseat the crankcase halves ensure that the two dowel pins are properly engaged with mating holes in crankcase upper half e Refer to Figure 5 2 Install four 8 x 65 and six 8 x 45 attaching bolts washers and lockwashers Install the four lo
66. o the cylinder which is subsequently ignited by a spark plug and the resultant gas expansion utilized to produce the power stroke Some considerable care is taken in the design to ensure that the combustion takes place at a controlled rate but under certain conditions the charge will burn at a highly excessive rate producing abnormal gas temperatures and pressures in the cylinder This condition is called detonation and may therefore be defined as the rapid and uncontrolled burning of the chargewhich commences at the point of ignition by the spark plug and is completed prematurely over a very short movement of the piston 241 The causes of detonation are many and varied but all have the common effect of overheating the charge towards the spontaneous combustion temperature of the fuel Con sequently when the charge is further heated by compression and ignited by the spark the flame spread rate is very rapid indeed resulting in the formation of the high pressure wave which impinges on the combustion chamber surfaces to create the sound of detonation of pinging which is so familiar to many people 2 4 2 t cannot be emphasized too strongly that if detona tion is allowed to persist serious damage may result to the 2 3 2 3 Denso Ignition This magneto 15 used on all models of the CCW 440 engine It is functionally similar to the Kokusan ignition described in 2 3 2 2 and the Kokusan Schematic at the bottom of page 2 3 applies
67. omodate the installation of oversize pistons Refer to Table 3 1 for standard and oversize fits and tolerances he oversizes listed in the table are the maximum allowable Discard cylinders that require boring in excess of tolerance shown Replace with serviceable cylinders NOTE Rebored cylinders should be honed with a fine finishing stone 3 3 11 Pistons Pins and Rings b Inspect pistons pins and rings for scoring and wear piston crowns for pitting evidence of corrosion and distortion Check diameter of pistons pins and pin bore piston ring end and side clearances Refer to Table 3 1 for method of inspection and tolerances Discard any parts that fail to meet applicable specifica tions and note the following 1 cylinder has been inspected and found serviceable replace defective piston with new standard size piston 3 9 2 If cylinder has been rebored and honed replace defective piston with oversize piston as listed in Table 3 1 3 3 12 Crankshaftand Connecting Rods a b 3 Check connecting rod twist as Check connecting rod tilt as 3 Inspect threads on each enu of shaft The mating nut the flywheel end of the shaft should turn on all the way by hand without excessive looseness Use a suitable thread cleaning tool to remove burrs from the threads Replace worn nuts Check tapered surface of flywheel end of shaft for scoring and wear When placed on the
68. properly gapped or dirty new points 6 Weak coil or condenser 8 Replace coil or condenser 7 Improper fuel mixture 7 Refuel using specified 1 Too much oil fuel oil mixture See Table 1 1 2 Too little oil 8 Leaking crankshaft seal 8 Replace seal Missing at high speed 1 Spark plugs improperly gapped 1 Clean adjust or install new or intermittent spark or dirty plugs 2 Loose or broken magneto wires 2 Repair or replace wires 3 Magneto breaker points improperly 3 Clean adjust or install or dirty new points 4 Weak coil or condenser 4 Replace coil or condenser 5 Heat range of spark plug 5 Install specified spark plugs incorrect 8 Leaking head gasket 6 Replace head gasket 7 Engine improperly timed 7 Re time engine Coughs spits slows 1 Idleorhigh speed jets 1 to 5 down surges too lean Adjust carburetor or fuel pump 2 Leaking gasket flange Refer to Manufacturer s Specifications 3 Inlet control lever set too low 4 Pulsation line obstructed 5 Fuel pump not supplying enough fuel due to 1 Punctured diaphragm 2 Inoperative flapper valve 6 Crankcase not properly sealed 6 Reseal crankcase 7 Idleor main carburetor nozzle 7 Refer to Manufacturer s obstructed Specifications 8 Fuel line obstructed 8 Remove fuel line Clear obstruction Replace line 9 Carburetor inlet needle and 9 Refer to Manufacturer s seat abstructed Specifications 10 Welch plug leaking 10 Refer to Manufa
69. pulley and recoil starter i Replace spark plugs check engine for proper operation Using a Stroboscope chet ignition timing setting auto advance mechanism Awhen fully advanced in accordance with specifications Table 1 1 5 4 4 2 Alternate Method See Figure 5 14 As an alternate method of engine ignition timing use the two sets of reference marks on the flywheel and the top dead center zero reference line marked on the fan cover The reference marks on the flywheel include a T which indicates piston position at top dead center when aligned with the zero reference line fan cover and 50 80 and 100 reference lines in advance of top dead center One set of reference lines is 1800 opposed to the other set If using the alternate method time the engine as follows a Remove spark plugs disconnect ignition at coupler b Remove recoil starter starter cup and fan belt pulley Remove window plate if installed c Refer to Figure 5 13 Adjust No 1 cylinder contact breaker point gap to 0 014 inch This point set has white ignition wiring Connect one lead of a timing light having a self contained battery or suitable instrument to the white wire at coupler and the other lead to ground Rotate flywhee until No 1 piston is approaching top dead ceriter and the nearest 89 reference line is aligned with the zero reference line on the fan cover At this 5 8 instant the timing light should go out or suita
70. re 5 4 b Install new base gaskets over cylinder hold down studs Cylinders are identified by the letters L left hand and right hand stamped the cylinder flange Locate right hand No 1 cylinder at flywheel end of crankcase Lubricate pistons rings and cylinders with two stroke engine oil d Place a suitable wooden block between piston and Piston Rings Fig 5 3 Installing Pistons Rings and Pins 5 2 F 9 crankcase to steady the piston Using piston ring compressing tool compress rings flush with piston Slide cylinder over piston and ring assembly Remove ring compressing tool Repeat steps c d and e for No 2 cylinder Install cylinders on the crankcase and fit flat washers spring washers and securing nuts Tighten the nuts evenly to hold the cylinders firmly on the crankcase REPLACEMENT PAGE MARCH 1971 DO NOT TIGHTEN TO FULL TORQUE AT THIS STAGE Install inlet manifold using new gaskets and tighten securely to ensure alignment of the cylinder and manifold flanges Finally tighten the cylinder flange nuts as per Figure 5 5 to recommended torque of 15 18 Ibs ft Fig 5 4 Installing Cylinders Power Take Off End Flywheel End Fig 5 5 Cylinder Hold down nut torquing sequence 5 3 5 2 4 Cylinder Heads See Figure 5 6 a Instal new cylinder head gaskets over cylinder head hold down studs b Install cylinder heads over
71. rm i pem HH ift di E E EE E bp dos nd po MADE IN CANADA 2 9 10 x 10 TO THE 1 2 INCH 68 12 222225521 SE Ee HHHH H H Lj qp upper E E Ep pn EE q E E 2 ECEUN LI Te 1 o i H in EH LL x t EE gt Er iE HE H HE is sawas arene LI H EF N 2252252 t cs NS EE ERE E 1 HR an 1 i ZER MENE DUM ute oo p yY HANG cH EHE LI T asana rL Cr RE
72. rocedure CAUTION Ensure no lubricant gets on breaker points during installation Contaminated points will urn during engine operation c Adjust poin Paragrapl s 10 specified gap Refer to Section V 5 4 3 4 7 2 Condensers and Felt Pads NOTE Removal and installation procedure is applicable to both condensers 4 7 2 1 Removal a Loosen electrical terminal connector 32 at contact breaker point set 7 Disconnect the condenser lead wire 4 10 Remove retaining screw 15 or 19 as applicable and washer 16 securing condenser to coil plate 2 Remove condenser and oil felt pad if attached Check pad for condition and replace if lubricating capacity is question able 4 7 2 2 Installation a Heverse removal procedure b Lubricate oil felt pad Refer to Lubrication Chart Table 2 2 4 8 CRANKSHAFT See Figure 4 7 NOTE If inspection reveals maintenance requirements be yond outer ball bearing or outer oil seal removal and installation install a new crankshaft 4 8 1 Oil Sealand Outer Bearing 4 8 1 1 Removal a Remove Woodruff key 14 from tapered end of crank shaft assembly using suitable pliers or removal tool Remove oil seals 3 and 4 Seals are a snug fit and can be removed by sliding them along the shaft Discard seals Remove outer bearings 2 one from each end of crankshaft using bearing puller or suitable removal tool 4 8 1 2 NOTE Keep bearings in the packaged con
73. securing condenser and oil felt pad 8 to coil plate 2 Remove ondenser and oil felt pad Check pad for condition and replace if lubricating capacity is questionable 2 2 Installation Reverse removal procedure Resc rimary coil and ignition coupler Secure condenser primary wire to contact breaker set at terminal connector 28 Lubricate oil felt pad Refer 2 2 4 7 STATOR ASSEMBLY KOKUSAN MODELS 340E 3406 and ALL 400 MODELS See Figure 4 6 NOTE Complete disassembly of stator assemblies should be performed by authorized dealers only Normal dis assembly should be restricted to removal and replace ment of contact breaker point sets oil felt pads or condensers If inspection reveals additional main requirements install a new assembly or return stator to overhaul facility a b Ider condenser wires at point Lubrication Chart Table 4 7 1 Contact Breaker Point Sets NOTE Removal and installation procedure is applicable to both point sets 4 7 1 1 Removal Loosen electrical terminal connector 32 securing igni tion wiring at contact breaker point set 7 Disconnect the wires b Remove retaining screw 18 or 20 as applicable lockwasher 16 and washer 17 securing breaker point sel to plate 2 Remove breaker point set 4 7 1 2 Installation Apply a light film of Lubriplate or equivalent to pivot shaft b Reverse removal p
74. shaft hand tight the flywheel should not wobble Inspect keyway and Woodruff key for damage and wear Replace worn keys Inspect ball bearings for wear free movement and security Using Vee blocks 2 on a flat surface support the crankshaft on the center main bearings Mount dial indicators et Junction of tapered and parallel sections of the shaft and rotate crankshaft by the connecting ruds Refer to Table 3 1 for tolerances Check crankshaft for bend or twist on the crankshaft journals Use a dial indicator placed on the main bearing journals Zero the indicator Rotate crankshaft one full turn Refer to Table 3 1 for tolerances Check connecting rod diameter at small end side and vertical clearance at large end Refer to Table 3 1 for method of inspection and tolerance follows 1 Insert a bar 100 mm long or any other convenient length into the connecting rod small end Centralize ihe rod using a depth gauge and lock in position 2 Support connecting rod horizontally Using a dial indicator measure the maximum height at opposite ends of the bar when the rod is twisted to the right and to the left Any variation indicates connecting rod twist Refer to Table 3 1 for tolerance follows 1 Repeat step h 1 2 Support connecting rod vertically Using a dial test indicator measure ihe amount of movement at ends of bar when bar is tilted to the right and to the left The difference bet
75. strokes of the piston the complete cycle of a fuel air induction b compression of the fuel mixture c combustion d exhaust of the burned gases b The construction of the engine requires a sealed crankcase and a cylinder having four carefully positioned ports as follows 1 Carburetor inlet for induction of the fuel air mixture 2 Two transfer ducts leading to transfer ports for transferring the mixture from the crankcase to the combustion chamber 22 SEQUENCE OF OPERATION see Figure 2 1 3 Exhaust port for exhausting the burned gases c The first stroke of the piston from bottom dead center a As the crankshaft rotates the piston moves from the 0 to the top dead center 0 has two B D C position thus creating a depression or partial functions vacuum in the crankcase When the piston uncovers the Fig 2 1 M COMPRESSION COMBUSTION FUEL TRANSFER LOOPSCAVENGE AND OF INDUCTANCE CHARGE carburetor inlet port fuel air mixture metered by the carburetor isadmitted to the crankcase b Continued upward movement of the piston will compress the charge in the combustion chamber until at a point near T D C the spark from the spark plug will ignite the mixture c Resultant expansion of the ignited fuel will push the piston toward B D C Moving downward the piston first uncovers the exhaust port and allows the hot gases still under considerable pressure to escape to atmosphere through the exhaust
76. system d Continuing downward the piston will now uncover the two transfer ports and close the carburetor inlet port The mixture in the crankcase and lower part of the cylinder is displaced by the piston and conducted through the transfer ducts to the combustion chamber above the piston The fresh charge entering through the two transfer ports will form a loop see Figure 2 10 thus scavenging the cylinder of burned gases e The cycle will repeat continuously as from paragraph a until the engine ignition is switched off 2 3 IGNITION SYSTEM 2 3 1 General The ignition system used with model CCW 340 and CCW 400 engines is basically the same as systems used with most conventional two stroke engines It consists of a low tension magneto two high tension ignition coils two ignition spark plugs spark plug high tension lead wires an ignition switch and the required electrical wiring Model 3405 engines differ from 340E 3406 and 400 engines in magneto design Magnetos in use on the model 3405 incorporate only one low tension generating coil All other models covered in this manual use two low tension generating coils Refer to paragraphs 2 4 2 1 and 2 4 2 2 2 3 2 Description The magneto assembly is mounted to the engine crankcase at the flywheel end It functions to generate low tension impulses in the primaries of the ignition coils Two sets of contact breaker points one set for each cylinder are installed in the magneto
77. t enough oil in gas cylinders Loss of 2 Lack of cooling compression 2 Blown head gasket 2 Replace head gasket 3 Loose spark plug 3 Check plug for security 4 Head bolts not tight enough 4 Torque head bolts to proper specifications Engine won t crank 1 Piston rusted to cylinder wall 1 Remove piston and cylinder over Unable 10 rotate Replace defective parts flywheel 2 Crankshaft seized to bearing 2 amp 3 Disassemble engine main or rod Replace defective parts 3 Broken connecting rod 4 Flywheel seized to coil plate 4 Remove flywheel Replace defective parts 5 Engine improperly assembled after 5 Recheck re assembly procedure repair 2 7 OPERATING INSTRUCTIONS NOTE if the engine fails to start after repeated attempts refer to Trouble Shooting Chart Table 2 1 2 1 1 Preparation For Operation Ensure that the fuel tank is filled with thecorrect mixture of recommended gasoline and special air cooled two stroke 2 1 2 2 Starting the engine using electric starter engine oil See Table 1 1 a Adjust throttle lever to approximately one half full open CAUTION When filling or opping up the fuel tank use position iuel strainer to prevent possible contamination b Close carburetor choke lever When starting a warm engine af engine and fuel system components it may not be necessary to close the choke Engage the applicable ignition switch If engine does not Start within 5 seconds disengage the ignitio
78. th the primary windings of the ignition coils Operation of the ignition switch to the RUN position opens a circuit between the windings and allows the contact breaker points to control the ignition circuit The flywheel incorporates four permanent magnets and a breaker point cam and auto advance mechanism In opera tion as the flywheel rotates an electrical current is generated in the low tension generating coil The rotating breaker point cam activates the breaker points opening and closing them in accordance with a timed ignition sequence Refer to Section paragraph 5 4 4 Closing the points causes the buildup of a magnetic field in the ignition coils Opening the points causes a very rapid collapse of the field thus inducing a high voltage current in the secondary windings of the coil High tension spark plug wires conduct the high voltage current to the spark plugs Self induced high voltage current in the primaries is momen tarily stored in the condensers to prevent arcing across the point contacts When the contacts next close the condensers will discharge back to the ignition coils thus assisting in the buildup of the magnetic field in the coils The ignition circuit will continue to function until the ignition switch is turned to the OFF position which will maintain a circuit and prevent ignition 24 DETONATION The internal combustion engine is designed to induce a combustable mixture of gasoline and air int
79. the touch 1209 1400 F Use a soft drift to push the pins out from the opposite side Remove needle bearings 10 from connecting rods small end CAUTION Exercise care when removing piston pins 10 prevent damage to needle bearings Keep bear ings adequately protected until time of assem bly Figure 3 11 p Remove piston rings from piston ring groove using suitable ring removal tool 4 Remove the ten bolts plain washers and lockwashers joining the two halves of crankcase Separate crankcase by pulling the two halves apart Remove the crankshaft Remove the four seal retaining circlips from crankcase lower half Refer to Section figure 5 1 CAUTION Do not use a screw driver to pry the crankcase apart If necessary use asoft hammer and tap the case lightly on either end Figure 3 12 3 3 CLEANING AND INSPECTION 3 3 1 Cleaning Prior to inspection clean all parts except the magneto assembly by immersing and soaking in a suitable cleaning solvent or using specified methods Clean the crankshaft before other components to protect bearings from possible damage due to dirty cleaning solvent Thoroughly dry all parts after cleaning Pay particular attention to the following a Spark plugs Remove light carbon deposits by brushing lightly with a wire brush If plug is excessively dirty and proper cleaning equipment is not available install a new spark plug b
80. uya plugs from spark plug holes install open tied plugs and connect high tension leads engine for proper operation Refer to paragraph fencing to applicable mounting location attach tailpipe connect electrical wiring and cur and Chock eed 8 3 TESTING AFTER OVERHAUL 5 3 1 General dive do ten percent power 1088 may be expect dona i newly id until it has been subjected to suitahle period Carefully run the engine al va rin ig engine ati to firs twenty five hours of operation J 5 4 ADJUSTMENTS 5 4 1 Carburetor Refer to applicable manufacturer s specifications 5 4 2 Spark Plugs Refer to Section Paragraph 3 3 4 5 4 3 Contact Breaker Points See Figure 5 13 a Remove recoil starter starter cup and fan belt pulley Remove window plate Kokusan magneto only Loosen applicable breaker point retaining screw Adjust breaker points gap to 0 014 002 inch Use a feeler gauge to measure the gap Tighten breaker point retaining screw Check engine ignition timing See Paragraph 5 4 4 g Replace window plate starter cup fanbelt pulley recoil starter c and 5 4 4 Engine Ignition Timing See Figure 5 14 After engine overhaul or whenever contact breaker points have been replaced or adjusted check and or adjust ignition timing to ensure continued engine operating efficiency 5 4 4
81. ween the two readings indicates the amount of tilt Refer to Table 3 1 for tolerance 3 13 Crankcase Inspect crankcase mating surfaces for deep scratches scoring and pitting Inspect bearing and oil seal retaining inserts for wear scoring or conditions which could cause leaks Inspect attaching dowel pins for wear and security Discard crankcase if normal repair procedures are not sufficient to correct defects 3 14 Fitsand Tolerances Table 3 1 lists standard fits and tolerances to be checked during inspection of pistons piston pins cylinders and crankshaft t also lists allowable oversizes of pistons and rings If suggested method of inspection is not available use suitable measuring devices 1971 CCW Model 340 400 TABLE 3 1 FITS AND TOLERANCES Tolerances Std Size Inches Method of Component In Mm Minus Plus Remarks nspection Cylinder CCW 340 2 36 60 0007 Dial Indicator CCW 400 2 56 65 N A 0007 CCW 440 2 67 68 N A 0007 Connecting Rod small end 867 22 N A 0003 Dial Indicator 0008 big end 1 261 32 0004 001 side clearance 014 N A 018 vertical clearance N A 0004 Dial Indicator 0015 twist 003 Measured at ends of bar Dial Indicator 3 94 centred in small end See Manual bend N A 001 Crankshaft 0035 Measured at junction Dial Indicator permissable misalignment due of taper and parallel to bend or twist sections see manual Crankshaft e
82. yzers b taste u Secure high tension Ignition coils to fe isi two 6 x 65 attaching bolts and spacers Corin tension wires to ignition coupler iusiuli aud secure coil cover using two 6 x 10 bol washers atid lockwashers Figure 5 11 n ect low s 12 5 2 10 Recoil Starter See Figure 5 12 a ami secure recoil starter to fan cover using Tour 6 at washers and lockwashers 5 2 11 Intake and Exhaust Manifolds two new intake manifold gaskets and the two over intake manifold hold down studs d additional new gaskels over insulators anc mount intake manifold to hold down studs Secure with mr 5 lockwashers and hold down nuts Do wertorgue the nuts H ME new exhaust manifold gaskets and mount manifold hold down studs Secure with four lockwashers and hold down nuts Quat wertort ue the nuts 5 2 12 Cavers and secure cylinder cover and adapter to engine four b x 19 and six 6 x 12 attachment bolts and locrwashers install the four shorter bolts at intake and exhaust manifold sides of cover Start each atta chment before tightening any bolts then tighten ail bolts Ensure spark plug wires are properly secured as shown in figure 5 12 5 2 13 Engine Installation a mia tar tral R

1971 CCW 340 Service Manual

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